A coil assembly, a method of manufacturing a coil assembly, and a contactor

Abstract

This invention provides a coil assembly, a method for manufacturing the coil assembly, and a contactor. The coil assembly includes a coil frame, a metal wire, and terminals. The coil frame includes a winding shaft and flanges connected to both ends of the winding shaft. The flanges are provided with insertion interfaces and winding posts. The metal wire is wound around the winding shaft and winding posts of the coil frame to form a coil. The terminals have a insertion portion, a connection portion, and an overlap portion. The insertion portion is inserted into the insertion interface of the flange, the connection portion is suspended outside the flange and extends into the winding window, and the overlap portion overlaps the winding post and forms electrical contact with the coil. Thus, the metal wire can be pre-wound onto the coil frame to form a coil, and then the terminals can be assembled. This allows the connection portion to extend into the winding window to reduce the overall height without affecting the coil winding; that is, a simple structure achieves a high-compression effect for the product.

Description

Technical Field

[0001] This invention relates to the field of electrical devices, and more specifically to a coil assembly, a method for preparing the coil assembly, and a contactor. Background Technology

[0002] A DC contactor is a type of contactor used in DC circuits, primarily for controlling DC circuits such as main circuits, control circuits, and excitation circuits. Due to installation requirements, the contactor's coil terminals need to have screw holes in multiple directions on their exterior. To avoid interference with the coil winding, the current approach is to position the lowest surface of the coil terminal above the coil winding window. Examples include a DC contactor disclosed in CN108550503B, and a coil terminal and DC contactor with such a terminal disclosed in CN209298026U. However, this design results in wasted space in the height direction of the coil frame and the upper surface of the coil terminal. This wasted space is determined by the required space in the height direction of the coil terminal, making the contactor too tall and limiting the product's usable space requirements. Summary of the Invention

[0003] To address the aforementioned problems, this invention provides a coil assembly, a method for preparing the coil assembly, and a contactor.

[0004] To achieve the above objectives, the technical solution provided by the present invention is as follows:

[0005] A coil assembly includes a coil frame, a metal wire, and a terminal block. The coil frame includes a winding shaft and flanges connected to both ends of the winding shaft. A winding window is defined as the space around the outer periphery of the winding shaft. The flanges are provided with a connector and a winding post. The metal wire is wound around the winding shaft and the winding post of the coil frame to form a coil. The terminal block has a connector portion, a connection portion, and an overlap portion. The connector portion is inserted into the connector of the flange. The connection portion is suspended outside the flange and extends into the winding window. The overlap portion overlaps the winding post and forms electrical contact with the coil.

[0006] Furthermore, the plug-in part and the wiring part are arranged opposite to each other and connected by a connecting part, and the plug-in part, the connecting part and the wiring part together form an inverted "U" shaped main body.

[0007] Furthermore, the overlapping portion is connected to the connecting portion and extends outward on the side opposite to the wiring portion.

[0008] Furthermore, the length of the plug portion in the plugging direction is smaller than that of the wiring portion.

[0009] Furthermore, the length of the plug-in portion in the plugging direction is half that of the wiring portion.

[0010] Furthermore, the overlapping portion is a long, thin strip structure.

[0011] Furthermore, the overlapping portion and the winding post are also fixed by welding.

[0012] Furthermore, the flange of the coil frame is provided with a mounting boss, the top of the mounting boss is provided with the insertion interface, the winding post is fixed on the mounting boss and extends laterally out of the mounting boss.

[0013] A method for preparing a coil assembly includes the following steps:

[0014] S1, a coil frame is provided, the coil frame including a winding shaft and flanges connected to both ends of the winding shaft, the flanges being provided with insertion interfaces and winding posts;

[0015] S2, the metal wire is wound around the winding shaft and winding post of the coil frame to form a coil;

[0016] S3 provides a terminal block having a plug portion, a wiring portion and an overlap portion. The plug portion is inserted into the plug interface of the flange, the wiring portion is suspended outside the flange and extends into the winding window, and the overlap portion overlaps the winding post and forms electrical contact with the coil.

[0017] Furthermore, in step S3, the overlapping portion and the winding post are also fixed by welding.

[0018] A contactor comprising a magnetic circuit portion and a contact portion, wherein the magnetic circuit portion employs the coil assembly described above.

[0019] Furthermore, the contactor also includes an auxiliary contact. The two flanges of the coil frame are an upper flange and a lower flange, the terminal block is mounted on the upper flange, and the auxiliary contact is mounted on the lower flange.

[0020] The technical solution provided by this invention has the following beneficial effects:

[0021] By directly setting the winding post on the coil frame, the terminal block overlaps the winding post through the overlapping part and forms an electrical contact with the coil; in this way, the metal wire can be wound on the coil frame to form a coil before the terminal block is assembled. In this way, without affecting the coil winding, the terminal block can be inserted into the winding window to reduce the overall height; that is, the effect of product height compression is achieved through a simple structure. Attached Figure Description

[0022] Figure 1 The diagram shown is a structural schematic of the coil frame in the embodiment;

[0023] Figure 2 The diagram shown is a structural schematic of the wiring terminals in the embodiment.

[0024] Figure 3 The diagram shown is a schematic representation of the structure of the coil wound on the coil frame in the embodiment.

[0025] Figure 4 The figure shown is a three-dimensional structural diagram of the coil assembly in the embodiment;

[0026] Figure 5 The image shown is a side view of the coil assembly in the embodiment;

[0027] Figure 6 The diagram shown is a partial structural schematic of the contactor in the embodiment. Detailed Implementation

[0028] To further illustrate the various embodiments, the present invention provides accompanying drawings. These drawings are part of the disclosure of the present invention, primarily used to illustrate the embodiments and to explain the operating principles of the embodiments in conjunction with the relevant descriptions in the specification. With reference to these drawings, those skilled in the art should be able to understand other possible implementations and the advantages of the present invention. Components in the drawings are not drawn to scale, and similar component symbols are generally used to represent similar components.

[0029] In the description of this invention, terms such as "upper," "lower," "left," "right," "front," and "rear," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0030] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments.

[0031] Reference Figures 1 to 5 As shown, this embodiment provides a coil assembly including a coil frame 10, a metal wire, and a terminal block 20. The coil frame 10 includes a winding shaft 11 and flanges 12 connected to both ends of the winding shaft 11. The flanges 12 are provided with a connector 14 and a winding post 15. The space around the outer periphery of the winding shaft 11 is defined as a winding window 101. The metal wire is wound around the winding shaft 11 and the winding post 15 of the coil frame 10 to form a coil 30. The terminal block 20 has a connector 21, a wiring portion 22, and an overlap portion 24. The connector 21 is inserted into the connector 14 of the flange 12. The wiring portion 22 is suspended outside the flange 12 and extends into the winding window 101. Specifically, the wiring portion 22 has multi-directional threaded holes for connecting external wiring, and the lowest surface of the wiring portion 22 can be within the winding window 101. Figure 5As shown, the distance H from the lowest surface of the wiring portion 22 extending into the winding window 101 is the compressed height of the coil assembly. The overlapping portion 24 overlaps the winding post 15 and forms electrical contact with the coil 30. In this specific embodiment, the overlapping portion 24 is a long, thin strip structure that overlaps the winding post 15.

[0032] This embodiment also provides a method for preparing the above-mentioned coil assembly, including the following steps:

[0033] S1, provides such as Figure 1 The coil frame 10 shown includes a winding shaft 11 and flanges 12 connected to both ends of the winding shaft 11. The flanges 12 are provided with insertion interfaces 14 and winding posts 15; that is, the winding posts 15 are directly assembled on the flanges 12 of the coil frame 10.

[0034] S2, the metal wire is wound around the winding shaft 11 and winding post 15 of the coil frame 10 to form a coil 30, such as Figure 3 As shown; at this time, the coil frame 10 is not equipped with the terminal 20, so the winding of the coil 30 will not be affected by the terminal 20.

[0035] S3 provides, for example Figure 2 The terminal block 20 shown has a plug portion 21, a wiring portion 22, and a lap portion 24. The plug portion 21 is inserted into the plug interface 14 of the flange 12. The wiring portion 22 is suspended outside the flange 12 and extends into the winding window 101. The lap portion 24 laps on the winding post 15 and forms electrical contact with the coil 30. The finished product is as follows: Figure 4 and Figure 5 As shown.

[0036] This design allows the wiring part 22 to extend into the winding window 101 to reduce the overall height without affecting the winding of the coil 30; that is, it achieves the effect of product height compression through a simple structure.

[0037] In a further preferred embodiment, to ensure the connection stability of the overlapping portion 24 and the winding post 15, the overlapping portion 24 and the winding post 15 are also fixed by welding; that is, in step S3 of the preparation method, after the overlapping portion 24 and the winding post 15 are completed, they are fixed by welding. Welding provides further fixation and is simple to operate. Of course, in other embodiments, the overlapping portion 24 and the winding post 15 can be further reinforced by other methods.

[0038] The flange 12 of the coil frame 10 is provided with a mounting boss 13, and the insertion interface 14 is opened on the top of the mounting boss 13. The winding post 15 is fixed on the mounting boss 13 and extends laterally out of the mounting boss 13, thus realizing convenient installation of the terminal 20. Specifically, the winding post 15 can be assembled on the mounting boss 13 by in-mold injection molding, which is convenient for manufacturing. Of course, in other embodiments, other structures can also be provided on the flange 12 of the coil frame 10 to realize the installation of the winding post 15 and the terminal 20.

[0039] Specifically, in this embodiment, as Figure 2 As shown, the plug-in portion 21 and the wiring portion 22 are arranged opposite to each other and connected by a connecting portion 23. The plug-in portion 21, the connecting portion 23, and the wiring portion 22 together form an inverted "U" shaped main body. The use of inverted "U" shaped wiring terminals facilitates assembly. At the same time, the overlapping portion 24 is connected to the connecting portion 23 and extends outward on the side opposite to the wiring portion 22. That is, the overlapping portion 24 is located on the same side as the plug-in portion 21, which is equivalent to extending a slender overlapping portion 24 from the connecting portion 23, resulting in a simple structural design.

[0040] The insertion part 21 is in the insertion direction (i.e. Figure 2 The length of the connector 21 in the Y direction is smaller than that of the wiring portion 22. For example, in this embodiment, the length of the connector 21 in the insertion direction is half that of the wiring portion 22; the size of the connector 21 is sufficient to allow for insertion and fixing. The wiring portion 22 can maintain its existing size to accommodate the operation of external wiring.

[0041] Of course, in other embodiments, the structure of the terminal block 20 is not limited to this.

[0042] This embodiment also provides a contactor, a magnetic circuit portion and a contact portion, wherein the magnetic circuit portion adopts the coil assembly described above; thus, the overall height of the product can be effectively reduced.

[0043] Reference Figure 6 As shown, in another preferred embodiment, the contactor further includes an auxiliary contact 40, which is linked to the moving iron core of the magnetic circuit for indication. Specifically, the two flanges 12 of the coil frame are an upper flange 121 and a lower flange 122, the terminal 20 is mounted on the upper flange 121, and the auxiliary contact 40 is mounted on the lower flange 122. By separating the terminal 20 and the auxiliary contact 40, the auxiliary contact 40 does not affect the compression height effect achieved by the mounting of the terminal 20 in the position of the upper flange 121.

[0044] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A coil assembly, comprising a coil frame, a metal wire, and terminals, wherein the coil frame includes a winding shaft and flanges connected to both ends of the winding shaft, and a winding window is defined in the space surrounding the winding shaft. The coil frame is characterized by: The flange is provided with a plug-in interface and a winding post. The metal wire is wound around the winding shaft and winding post of the coil frame to form a coil. The terminal has a plug-in part, a wiring part and an overlapping part. The plug-in part is inserted into the plug-in interface of the flange. The wiring part is suspended outside the flange and extends into the winding window. The overlapping part overlaps the winding post and forms electrical contact with the coil. The plug-in part and the wiring part are arranged opposite to each other and connected by a connecting part. The plug-in part, the connecting part and the wiring part together form an inverted "U" shaped main body. The coil frame has a mounting boss on its flange, and the insertion interface is opened on the top of the mounting boss. The winding post is fixed on the mounting boss and extends laterally out of the mounting boss.

2. The coil assembly according to claim 1, characterized in that: The overlapping portion is connected to the connecting portion and extends outward on the side opposite to the connecting portion.

3. The coil assembly according to claim 1, characterized in that: The length of the plug-in portion in the plugging direction is smaller than that of the wiring portion.

4. The coil assembly according to claim 1, characterized in that: The overlapping part is a slender strip structure.

5. The coil assembly according to claim 1, characterized in that: The overlapping part and the winding post are also fixed by welding.

6. A method for preparing a coil assembly, characterized in that, Includes the following steps: S1, a coil frame is provided, the coil frame including a winding shaft and flanges connected to both ends of the winding shaft, the flanges being provided with insertion interfaces and winding posts; S2, the metal wire is wound around the winding shaft and winding post of the coil frame to form a coil; S3 provides a terminal block having a plug portion, a wiring portion and an overlap portion. The plug portion is inserted into the plug interface of the flange, the wiring portion is suspended outside the flange and extends into the winding window, and the overlap portion overlaps the winding post and forms electrical contact with the coil.

7. The method for preparing the coil assembly according to claim 6, characterized in that: In step S3, the overlapping part and the winding post are also fixed by welding.

8. A contactor, comprising a magnetic circuit portion and a contact portion, characterized in that: The magnetic circuit portion employs the coil assembly described in any one of claims 1 to 5.

9. The contactor according to claim 8, characterized in that: The contactor also includes an auxiliary contact. The two flanges of the coil frame are an upper flange and a lower flange, the terminal block is mounted on the upper flange, and the auxiliary contact is mounted on the lower flange.

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